Sterile container filling apparatus



Spt. 8,1970" A.s.TAY|.;QR ETAL 3,527,017

STERILE CONTAINER FILLING APPARATUS original Filed July 5, 1966 1ssheets-sheet 1 o Q 0 olllro n 0.o N .1 [l il 0 |||l SI -ai v a \.I|ll

. o o o @mi )o0 v 400000000 0000O0O0O0-00O /NVE' N 7' ORS. ARTHUR`Sl/VCLA/R TAYLOR E LLo` WORT H SANDHAGE GEORGE BOTT 1.

WILL /AM KONAZEWSK/ l ATTORNEY Sept.

A. S. TAYLOR ETAL STERILE CONTAINER FILLING APPARATUS Original FiledJuly 5. 1966 l5 Sheets-Sheet 2 ARTHUR S/NC'LA/R TAYLOR E'LLSWORTHASANDHAGE GEORGE HOTT W/LL/AM KONAZEWSK/ 8 MA/yam I. ATTORNEY Sept. 8,1970 A. S. TAYLOR ETAL STERILE CONTAINER FILLING APARATUS 13Sheets-Sheet 5 origirial Filed July 5,;196@

/NvEA/rons.

ARTHUR S//VCLA/R TAYLOR ELLSWORTH SANDHAGE GE ORGE BOTT WILL/AMKONAZEWSK/ ATTORNEY Sept 3i 1970 A.s. TAYLQR Al-:TAL 3,527,017

V STERILE CONTAINER FILLING APPARATUS original Filed July 5. 196e 13sheeis-sneei 4 sruFF//ve INVENTORS. ARTHUR Sl/VCLA/RV TAYLOR ELLSWORT HVSAIVRDHAGE GEORGE BOTT W/LL/AM KONAZEWSK/ A ATTORNEY swt-v8 1970 A. s.TAYLQR ETAL .3,527,017

STERILE CONTAINER FILLING APPARATUS `original Filed July 5. 195e 13sheets-sheet 5 /fvvE/vroRs. ARTHUR .s/NcLA/R TAY/.0R ELLs'woRrH SAND/A65GEORGE @arr w/LL/AM kofvAzEws/r/ ATTO/MIE Y Sept- 8 1970 A. s. #rAYLoRETAL 3,527,017

` STERILE CONTTINER FILLING APPARATUS @original Filed July s, 196e 13sheets-smelt e NVENTORS. .ARTHUR `SYNCL/I/R TAYLOR ELLSWORTH SANDHAGEGEORGE B077' WILL/AM KO/VAZEWSK/ Arron/vn Sept. 8,1970 A. s. TAYLORr-:TALl 3,527,017

n STERILE CONTAINER FILLING APPARATUS y original Filed July 5. 196e f'1s sheets-sheet v GEORGE BOTT W/L L/AM KONAZEWS/(l- Afro/wer sept. s,1910 'R 4 R Original Filed July v5*. 19.66

A. sv. TAYLOR ETAL. 1 3,527,017

S'I'ERILEk CONTAINER FILLING `APPARATUS NVENTORS. ARTHUR S/NCLA/R TAYLOREL LSWORTH SAND/'MGE GEORGE BOTT- WILL/AM KONAZEWSK/ Arron/ver Sept. 8,1970 A. s. TAYLQR ETAL 3,527,017

STERILE CONTAINER FILLING APPARATUS E original Filed July 5,. 196e 13sheetssheet 9 IN VE N T ORS. ARTHUR .Sl/VCL A /R 7A YLOR EL LS WORTHSANDHAGE GEORGE 5077' W/ L L IAM KONAZEWSK/ n I 77 v 75E 76 73 I 4 v n`74 y l l Arron/ver Sqn. s, 1970A A. s. TAYLOR ETAL 3,527,017 STERILECONTAINER FILLING ABPRATUS original Filed July 5.' 196e 15 sheets-sheet1o f. *II/00 g f 5:2. g' 13 /NvE/vroRs. y ARTHUR s//vc/.A/R. TAYLORfLLswoRrH SAND/m65 GEORGE Barr w/LL/AM KONAZEwS/r/ Ar'rokNEr l Sept V8,1970 A. s. TAYLOR :a1-AL. 3,527,017r

STERILE CONTAINER FILLING APPARATUS original Filed July 5. 196e I 15sheets-sheet 11 lll-llllllllllll` llmllii@ w NVENTORS.

ARTHUR S/NCLA/R TAY/.0R ELL SWORTH SANDHAGE GEORGE B077' W/LL/AMKO/VAZEWSK/ ATTORNEY A. s. TAYLOR ETAL 3,527,017

STERILE CONTAINER FILLING APPARATUS Original Filed July 5. 1966 sept. s,1970 13 Sheets-Sheet 12 INVENTORS. ARTHUR S//VCLA/R TAYLOR ELLSWORTHSANOHAGE GEORGE HOTT W/LL/AM KONAZEWSK/ ...L a@ AM Y ATTORNEY Sept 8,1,970 A -A. TAYLQR ETAL I 3,527,017

STERILE CONTAINER FILLING APPARATUS A-Oriuazinal Filed July 5. 196e 13sheets-'sheet 1s l IVVENTORS. AR THUR S/NCLA/R TA YLOR E LLSWORTHSANDHAGE GEORGE B077' WILL/AM KONZEWSK/ BY M Ward@ A T TORNEY UnitedStates Patent O 3,527,017 STERILE CONTAINER FILLING APPARATUS ArthurSinclair Taylor, Spring Valley, and Ellsworth Sandhage, Pearl River,N.Y., George Bott, Westwood, NJ., and'William Konazewski, Pearl River,N.Y., assignors to American Cyanamid Company, Stamford, Conn., acorporation of Maine Original application July 5, 1966, Ser. No.562,620, now Patent No. 3,453,804, dated July 8, 1969. Divided and thisapplication Apr. 2, 1969, Ser. No. 812,833 Int. Cl. B65b 57/10, 3/12U.S. Cl. 53-62 8 Claims ABSTRACT F THE DISCLOSURE An automatic,essentially continuous system for filling and stoppering containersincludes the following stations. The first station arranges a series ofempty containers, such as vials, into single file with open mouth up.The single file of containers is loaded onto a moving conveyor on whichthe single file of -containers is carried first to a filling stationwith filling nozzles for a predetermined number of containers in theline. After filling the conveyor moves the file along past means forrejecting containers which have fallen on their side to the stopperingstation. The whole system is maintained in a sterile environment untilthe filled and stoppered vials are loaded on the trays.

RELATED APPLICATIONS This application is a division of our priorapplication Ser. No. 562,620, filed July 5, 1966, now Pat. No. 3,453,-804, issued July 8, 1969.

BACKGROUND OF THE INVENTION The problem of filling containers such assmall vials with biologicals, such as vaccines, diagnostic agents,antibiotics, and the like, has presented a number of very seriousproblems. The most serious perhaps is the necessity for maintaining thewhole operation under conditions of sterility. This has required extremeprecautions in practice, and also when part or all of the operations areeffected batch-Wise and particularly manually, out put suffers severelyand cost is greatly increased. Up to now there has not been available apractical, all-automatic, continuous, sterile vial filling unit whicheliminates handling of the vials by hand during operation.

SUMMARY OF THE INVENTION It is perhaps the single most importantadvantage of the present invention in its general organizational aspectthat complete sterility can be maintained without compromising outputand Without requiring additional steps requiring expensive hand labor;the present invention will be described more particularly in connectionwith the filling of containers with biologicals under sterileconditions. It should be understood, however, that the production unitof the present invention in its broader aspects, as well as individualequipment used in the production unit, may be employed for the fillingof other materials into containers even though they may not be of suchnature as to require a completely sterile environment.

The present invention, in addition to the major possibility ofcompletely sterile operation, also effects important economies inproduction costs per container, aceuracy of container filling and thelike, regardless of whether the operation has to be carried out undercompletely sterile conditions. Also, it should be noted that individualelements going into the production unit, such as loading, vial filling,vial stoppering, and final automatic loading operations can be used bythemselves without Patented Sept. 8, 1970 being part of the productionunit which forms the subject matter of the organizational aspect of thepresent invention.. They will be described in conjunction with theproductlon unit, but the present invention is not limited thereto andthey constitute separate, specific aspects or sub-combinations of theinvention.

It is advantageous to provide continuous operation of the productionline unit, using this term in its practical sense, namely for automaticoperation at least through a relatively long cycle, such as for examplethe filling of a tray of vials and stoppering them, where the tray has arelatively large capacity, such as for example 1,000 or more vials.Within such a relatively long cycle the operation is continuous. Also,it should be understood that while certain of the individual elements ofthe present invention are operated continuously, certain other elementsare operated automatically intermittently, but the net effect of theWhole production line is a continuous production. Therefore, thisdescription is intended to apply to operations in which the overallresult is continuous even though certain individual steps or elementsmay be intermittently performed.

Another problem, which is particularly acute in the filling ofbiologicals into small containers, is the prevention of finally`discharging imperfectly filled containers, such as for example vialswhich may have fallen on their sides and spilled their contents. It isan advantage of the present invention, particularly in its generalorganizational modification as a production line unit, that provisioncan be, and in this specific aspect is, provided where- =by imperfectlyoriented or filled containers are automatically eliminated andpreferably spillage is automatically cleaned up and resterilization ordisinfection is achieved. Such a more complex but also more perfectmodification of the present invention is included in a specific aspectand may be considered as the best, and for many purposes the preferred,modification of the invention. lt is an advantage of the flexibility ofthe present invention that the elimination of spilled or imperfectlyoriented containers may be used wherever this automatic action isdesired Without affecting the other features of the production unitoperation. ln the more detailed description of the invention inconjunction with the drawings there Will be described a production linein which the automatic rejection of spilled or imperfectly orientedcontainers takes place between the filling station and the stopperingmechanism. A similar ejection can be introduced before the containersreach the filling station. The present invention includes productionsystem in which automatic ejection of imperfectly oriented containers isdispensed with or is provided before or after the filling station orboth.

One may consider that the automatic, and essentially continuous, fillingof containers involves a certain general sequence of operation,including loading of containers in the proper sequence and orientation,precise filling with a predetermined amount of liquid, insertion ofstoppers either completely, or partially, where escape of vapors insubsequent treating operations is required, such as for example withmaterials which are to be vacuum freeze dried, and finally, counting andloading the filled, stoppered containers into suitable loading units,such as trays. The description of the invention will follow this generalsequence, and the preferred automatic, essentially continuous operationof the production unit or line by control of some of the steps, such asfor example filling, from other operating steps or elements, such asstoppering, is effected.

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1A and 1B are a plan view,extended over two sheets of drawings, of the whole production line;

FIG. 2 is a vertical section of the drive of an antibridging mechanismfor empty container loading;

FIG. 3 is a plan view of a portion of the empty container loadingmechanism showing the anti-bridging device of FIG. 2 in plan;

FIG. 4 is an isometric view, partly in section, of the container fillingmechanism;

FIG. 5 is a detailed section along the line 5-5 of FIG. 4;

FIG. 6 is an elevation of the tipped over container rejecting mechanism;

FIG. 7 is an elevation of the stoppering mechanism;

FIG. 8 is a similar elevation, partly broken away and shown in section,of the stoppering mechanism taken at right angles to FIG. 7;

FIG. 9 is an elevation, partly broken away and in section, of a detailof one of the stopper carrying elements shown in FIG. 8;

FIG. l0 is a plan View of the stopper transport wheel of FIG. 7;

FIG. 11 is a section along the line 11-11 of FIG. l0;

FIG. 12 is a plan view of the container orienting and clamping wheel ofFIG. 7;

FIG. 13 is a section along the lines 13-13 of FIG. l2;

FIG. 14 is an elevation, partly in section, along the line 14-14 of FIG.16;

FIG. 15 is a similar view at a later stage of operation;

FIG. 16 is a plan view of the tray row transporter; and

FIGS. 17 to 19 are elevations, partly in section, of three differentpositions of the tray row loading mechamsm.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The general organization orproduction line aspect of the present invention will be specificallydescribed in conjunction with the loading of small vials with biologicalliquids under conditions of sterility. As can be seen on FIG. 1A,sterilized vials, open end up, are loaded from trays 1 onto a slowlyrotating plate 2 which forms part of a conventional bottle loader which,in conjunction with the usual fenced track 3 at one point of itsperiphery, aligns the vials in what is hoped to be uniform single le.The conventional loader, parts of which are used in the presentinvention, is also provided with a new antibridging device, which willbe described in more detail below in connection with FIGS. 2 and 3, andwhich prevents bridging and hence empty spaces in the line of vialsformed.

A whole tray of vials, for example containing 1200, are moved onto theslowly rotating plate 2 of the vial loader by pushing in theconventional manner. FIG. 1A shows a full tray ready to be pushed ontothe loader. This portion of the loader is not new with the presentinvention and is, therefore, shown diagrammatically. The vials arepushed through a low opening into the loader, which is covered, as isall of the production unit track with a cover 151 which is, for the mostpart, broken away, and this permits the maintenance of sterileconditions in ways which are, in themselves, known. Thus, for example,sterilizing ultraviolet radiation from suitable sterilamps1 showndiagrammatically at 152 maintenance of a slight positive pressure ofltered and preferably sterile air and the like. As these procedures arewell known, they are not specifically illustrated, and therefore FIGS.1A and 1B show the production line with most of the cover broken away sothat the successive operations are clearly shown.

FIG. 3 shows, on an enlarged scale, the phenomenon of bridging, whichoccurs with conventional vial loaders. As the vials are urged by theslowly rotating loader plate 2 against the guiding fence 3 at theperiphery, some vials can wedge themselves between two other vials toform a triangle. This is shown in FIG. 3 with two vials which are in theproper direction of the track shown at 4 and the slightly offset vialtouching them 5 forming a bridge. This phenomenon is, therefore, knownas bridging and is the bane of conventional vial loaders and aligners.

In FIG. 1A, and in detail in FIGS. 2 and 3, a new anti-bridging elementis shown. This is a small circular plate 6 with its axis eccentric tothe axis of the main loading plate 2. It is oscillated through a smallarc by a drive Wheel 7 which rolls on the plate 2. The wheel 7 isprovided with a projection 8, eccentrically located, on which a crankarm 9 is journaled. This in turn oscillates the anti-bridging plate 6through another crank arm 10. The drive wheel 7 is provided with an axle11 which is journaled in an arm 12, this arm being provided at its otherend with a pin 13 which is rotatable in a mounting 14 on a frame orplate 15. Pressure of the wheel 7 against the plate Z is provided by thebolt 16 which passes through a slot 17 in the arm 12. The framework 15is also adjustably mounted on a second framework 18 through the slottedarm 19 with bolt 20 and is supported at another point by a second arm 21which rests on the fence 3. This arm is also provided with a slot 22 andbolt 23 so that the exact position of the anti-bridging plate can beaccurately fixed in accordance with different vial sizes. It will beseen from FIGS. 2 and 3 that there is anti-bridging plate 6, which isbetween the framework 15 and the main rotating loader plate 2,projecting slightly beyond the framework 15 and so, when properlyadjusted, its oscillation will roll a bridging vial into line. Thiscompletely solves the `bridging problem and assures that the vials arelined up in single file and are moved onto a moving conveyor belt 24 asis shown on FIG. lA.

On the conveyor 24, which has a very smooth surface and may, forexample, be formed of polished metal plate links, the vials are moved inthe direction of the arrow between two guide rails 25 and 26 which forma track only slightly wider than the diameter of a vial. Track alignmentis maintained adjustably by the screws 27 and 28 and can be adjustedsimply for vials of different size. A sponge 29, which is preferablykept soaked with disinfectant, serves to wipe off any spillage on theconveyor 24 and to maintain it in a disinfected state.

As the vials move along their track they reach a fence 30 and a secondfence 31. The fences are controlled in synchronism with the fillingmechanism, which will 'be described further below, pneumatically orhydraulically by means of the cylinders 32 and 33. First the fence 31 isinserted, which stops the movement of the file of vials, and then thefence 30. Between them they hold in the track a predetermined number, asillustrated four, vials for lling. The conveyor 24 continues to move,but its smooth surface is such that it slides easily along the bottomsof the empty vials and does not cause any sticking. The movement of theconveyor 24 is continuous, as is that of the loading plate 2, and is notstarted. and stopped by signals from any of the mechanisms further alongthe line. The selection and retention of the four vials to be filled isbrought about by the fences 30 and 31.

The filling station is illustrated in FIGS. 4 and 5. The four vials areshown on the conveyor 24 in the upper right hand corner of the figure,but for simplicity the track and the two fences 30 and 31 are omitted.These serve, of course, to hold the four vials rigidly in positionduring the filling operation.

There are four filling nozzles 34 which are connected through four lines35, shown diagrammatically, to four pumps 36, two of which appear inFIG. 4 and one of which is shown in greater detail in the enlargedsection of FIG. 5. Suitable check valves 37 are in each line to preventbackflow of liquid in the lines 35. Each pump chamber 36 is connectedthrough its own inlet line 38 through check valve 39 to a bulk supply ofbiologica] shown in a container 40. Each pump chamber 36 is held againstvertical movement by a frame or plate 41, which is shown in FIG. 5. Thisis eliminated from the view in FIG. 4 in order not to obscure theillustration. The frame or plate 41 engages a shoulder of an enlargedportion 42 of each pump chamber. In this enlarged portion a taperingenlarged bore 43 forms a frustoconical chamber of predetermineddimensions.

The enlarged portion 42 of each pump chamber is surrounded by a cap 44,which may be of rubber or any other suitable elastomer. The whole fitstightly in an enlarged portion 45 of pumping elements 46 which aremounted in the cover 47 surrounding the whole of the mechanism. Lockingis effected by a suitable locking plate 48. Each enlarged head 45 has asecond frustoconical chamber of approximately the same shape as 43 inthe pump chamber itself. This is filled with a suitable liquid 49, whichmay be water, oil or any other incompressible liquid. In the restrictedbores of the members 46 there are accuratelydimensioned pistons 50. Eachpiston is of the same cross section. Means are provided to preventleakage of liquid around the piston rods 50, which can be associatedwith conventional stuffing boxes as indicated in FIG. 5. They are,however, not shown as they would interfere with the clarity of theillustration.

All four piston rods 50 are mounted in a rigid plate 51 which in turn ismounted on a single rod or shaft 52 journaled in a journal 53. Thedouble arrow in FIG. 4 indicates the oscillating travel of this shaft.At its lower end it is connected to a rigid rod 54 through a ball andsocket joint 55. The other end of the rod is mounted on a rotating plate56 through a second ball and socket joint 57. This plate is rotated bythe motor 58 through gears 59 and is journaled in a plate or framework60. This framework is capable of lateral movement but cannot tilt. Thelateral movement is determined by the four parallel arms 61 which arejournaled in the cover 47. In FIG. 4 two of these arms are shown in fulland two broken away. The arc of movement is indicated by the curveddouble arrow. The lateral position of the framework or plate 60 isdetermined by the threaded rod 612 which is threaded into a projection63 on the framework. The rod can be turned from outside of the wall 47by means of thehand wheel 64. Adjustment of the position of theframework 61 determines the stroke of the rod 52, which is variable inorder to pump different amounts of liquid 49 depending on the adjustmentof the wheel 64. It will be noted that there is an additional advantagevthat the whole mechanism within the wall 47 is kept from contact withthe outside, which aids in preventing contamination. Access to themechanism for periodic maintenance is through an opening (not shown).

It will be noted that the lowermost position of the rod 52 and thereforethe pistons 50 is fixed regardless of adjustment of the hand wheel y64.Movement of the framework 60 results in a vertical displacement so thatthe lowermost position of the rod 52 remains fixed. In other words, thevariation in the stroke of the pistons 50 is brought about by the changein the topmost position which they reach with different lateraladjustments of the position of framework 60. A single adjustment by thehand wheel 64 effects this change or adjustment in the amount of liquid49 pumped -without requiring any second adjustment of the lowermostposition that the rod 52 reaches. This is a practical advantage asvarying volumes of liquid can be pumped with a single adjustment insteadof requiring more than one as in many other filling devices. Adjustmentis simplified and complication is reduced to a minimum, which is apractical and important operating advantage. Another advantage that addsto simplicity and reliability is that the pumping mechanism which pumpsliquid 49 has no valves, which reduces risk of leakage or othermalfunction. The present invention should therefore not be confused, asfar as the filling operation is concerned, with more complicated pumpingmechanisms which require valves.

When a set of four vials are to be filled, a single revolution of theplate 56 causes the eccentrically located ball joint 57 to impart anupward and downward movement to the rod 52. This causes the four pistons50 to move up and down a definite amount which is accurately adjusted bythe wheel 64 to correspond to a particular volume which is to Ibe filledinto each vial. This is the only adjustment required. On the down strokethe elastic diaphragm 44 is pulled down to a horizontal position, whichsucks up liquid from the container 40 into each pump chamber. On thereturn up stroke an amount of liquid in each pump chamber 36, exactlycorresponding to the volume of liquid 4'9 moved by the piston 50, ispumped out through the check valves 37, lines 35 and orifices 34. Thisaccurately measured volume is thus transferred to each vial.

The motor 58 runs continuously but its cycle is adjusted by thecontroller 65 to a cycle time slightly greater than the time forstoppering four vials by the stoppering mechanism which will bedescribed below. One might say, therefore, that there is a roughsynchronism between the two operations, although exact synchronism isnot required at this point.

It should be noted that the pumping mechanism, including the fluid 49,does not come into contact with the biological which is pumped into thevials. There is a cornplete separation of the two systems by the elasticcaps 44. Sterility can therefore be maintained and there is nopossibility of either leaks or contamination. At the same time, the caps44 can be removed for cleaning and disinfecting, for example when adifferent biological is to be filled in, and of course at such time can.be replaced if desired. These elastic caps are relatively cheap, butthey do have a long life and so there is no risk of their failing byattempting to run them too near their normal life span. These featureswhich maintain complete sterility and at the same time completelyaccurate measuring out of the volumes filled into the vials are one ofthe most important advantages of the present invention, particularly inits aspect as a sub-combination including the filling mechamsm.

Another advantage is that the pressure of liquid over the elasticdiaphragms 44 is uniformly distributed, and since it is incompressiblean exactly measured amount is pumped each time. There is no problem ofvarying pressure by flexing of a diaphragm as in an ordinary diaphragmpump and thus, although it may appear at first sight as if the pumpsdescribed above resemble ordinary diaphragm pumps, they actually operateunder a different system, namely a perfectly uniform transfer ofmovement without any non-uniform flexing of the diaphragm. Ordinarydiaphragm pumps, While they would perhaps maintain sterility as long asthe diaphragms did not break, will not perform the exact measuring thatis effected in the present invention because the diaphragms are movedfrom portions and are therefore not subjected to a perfectly uniformliquid pressure over the whole of their surface. At the same time, oneof the advantages of ordinary diaphragm pumps, namely that they canhandle suspensions of solids and liquids, is fully maintained. In otherwords, the present invention not only performs a new result ofcompletely accurate measurement under sterile conditions, but this isobtained without any disadvantage and thus the present invention issuitable for filling suspensions of solids in liquids as well as pureliquids. This is a practical advantage as some biologicals or otherliquid materials do contain solids suspended therein.

After the four vials have ybeen filled, the fence 31 is retracted oncommand of the filling mechanism and the four vials proceed to moveforward in their track on the conveyor belt. When all four have passedthe location of the fence 31 the latter is moved forward and fence 30 iswithdrawn so that another set of four vials may move under the fillingnozzles and the filling sequence described above is then repeated.

The four vials now move to a portion of the track which providesdiscarding of vials which may have tipped over, This location, which isan abrupt jog, is shown at 66 in FIG. 1A and is illustrated in greaterdetail in FIG. 6. At the start of the jog the outer fence 26 isdeveloped into a portion 67 which contacts the upper parts of the vialsbut which leaves a space between it and the conveyor 24 that is greaterthan the diameter of the largest vial which is to be filled on themachine. As a result, if a vial tips and falls on its side, as is shownat 68, the conveyor belt causes it to slide underneath the portion 67 ofthe fence, and it is discharged into a bin 69. This position is shown indashed lines in FIG. 6. The vials which have remained upright are ofcourse held by the upper portion of the fence 67 and move on in theirregular single file, as can be seen at the right of FIG. 6.Theoretically the fence and the smooth surface of the conveyor beltshould preclude any vial tipping, and in practice this holds true formost 4 vials. However, in a large run an occasional one will tip, andthe discharge location 66 takes care of this situation. It will be notedthat if a vial tips onto its side the liquid will be discharged onto theconveyor belt, and this will move along the surface of the conveyor beltuntil it has reached the sponge 29, where it is wiped off and thedisinfectant in the sponge assures the maintenance of a sterilenvironment on the conveyor belt.

As has been pointed out above, the automatic ejection of tipped orimproperly oriented containers may be before the filling station insteadof after or in addition thereto. The mechanism is, of course, the samein its structure regardless of whether it is located in the portion ofthe track before or after the filling station. Therefore, no ejectionmeans is shown on the drawings before the filling station as this wouldresult in obscuring the drawing and would not add any information sinceit would involve merely a duplication of the mechanism at the dischargelocation 66. In a practical operating machine there is considerableadvantage in automatically ejecting improperly oriented vials bothbefore and after filling, and in such a machine of course the ejectionmechanism is duplicated at the other position.

At this point it is of interest to note that it is possible to operatemultiple lines of vials. This requires, of course, filling two tracks,doubled filling mechanisms as described above, duplicated tipped vialdischarge points, and duplication of the stoppering mechanism which willbe described below. Also, some minor modifications in the final loadingof stoppered vials are then required, as will be mentioned later. Noproblem is presented by the fences 30 and 31 because they move in fromthe outside, and of course the waste bins for tipped vials, shown n FIG.6, can be on the outside for each of the lines. Theoretically more thantwo lines could be filled at the same time.

which would require operating fences 30 and 31 from the top or otherwiseproviding for location of multiple actuating cylinders. The capacity ofthe system of the present invention is so high that adequate output isobtained with a single line, although in certain cases two lines can befilled simultaneously. The above discussion is primarily for the purposeof emphasizing that the present invention is not limited to filling asingle line of containers or even a pair of lines.

After passing the portion of the track 66, the row of vials reaches thestoppering mechanism. The location of this mechanism appears on FIG. 1A,but the description of the actual stoppering mechanism is bestunderstood in conjunction with FIGS. 7 to 13. First, however, referencewill be made to the loading of Stoppers in conjunction with FIG. 1A.There is a continuously oscillated loading plate 70 which moves Stoppers71 up inclined ramp 72 into single file properly oriented with theirtops down. The forward oscillation is slow and the return rapid. Thiskind of loader is not new with the present invention and is usuallycalled a vibratory bowl feeder. The loader for empty vials in FIGS. IA,2 and 3 is also not new, except for the antibridging mechanism. Sincethe bowl feeder is a known mechanism, its details are not shown in FIG.lA.

The Stoppers are moved into contact with a wheel 73, having scallops orteeth at its periphery of suitable size to receive a stopper. Therotation of this wheel and its relation to the bowl feeder 70 are bestseen in FIG. 1A, but the construction of the wheel is illustrated moreclearly in FIGS. l0 and 11. At the base of each scallop there is a smallport 74 connecting to a larger passageway 75. This is shown in dashedlines on FIG. 10 for several scallops and appears clearly in thesectional view of FIG. l1. At the ends of the passageways 75, they areprovided with short connections 76 which can communicate with a grooveor channel 77 in a stationary plate 78. This groove extends forapproximately half a circle, as can be seen in FIG. 10. It communicatesthrough an inlet conduit 79 with a source of vacuum, f not shown). Theplate 73 is turned by a shaft 80 driven in synchronism with the otherelements of the stoppering mechanism.

The vacuum in the scallops holds the Stoppers for approximately half ofthe wheel circumference until the Stoppers come over a vertical wheel81. This is best seen on FIG. 8, although the general relationship withother elements of the stoppering mechanism is also apparent from FIG. 7.The periphery of the wheel 81 is provided with uniformly placed openingsin which hollow plungers 82 can reciprocate. Each plunger has a hollowcenter 83 connected to its face through a channel 84. The periphery ofthe wheel 81 also has curved shoulders which define partiallydepressions 85 when the plungers are in retracted position. The centralbody is connected to a source of vacuum through a conduit 86 andcommunicating openings 87. As can be seen in FIG. 8, as the wheels 81and 73 turn, Stoppers are successively transferred from the wheel 73 tothe depressions partially defined by the shoulders 85 on wheel 81. Atthe point where the two wheels meet vacuum is released from the scallopson 73, as will be apparent from FIG. 8, and the suction through thechannels 84 in the plungers 82 suck the stoppers tightly against the endof each plunger. The shoulders 85 further aid in preventing the Stoppersfrom slipping out of position as the wheel 81 turns.

The present invention can handle any stopper of suitable size and theymay be solid Stoppers, such as illustrated at 88, or slotted Stoppers,as shown at 89. Of course, in any run of vials one kind of stopper wouldbe used, but both kinds are illustrated in FIG. 8. The solid stoppersare for vials which are to be tightly stoppered and the slotted ones forvials which are to be subjected to a treatment which causes escape ofvapors, such as freeze drying. Obviously, of course, after this latteroperation has been performed the split Stoppers are then forced infurther, but this is an operation which has nothing to do with thepresent invention. It is only mentioned as an example of the versatilityof the present invention, which can handle various designs of Stoppers.

Each plunger 82 is provided with a pin 90 extending through a slot 91and held in its normally retracted position by a spring 92. As the wheelS1 reaches the position immediately above a vial, which is held rigidly,as will be described below, the pin of the plunger contacts a cam 93 andis moved out, inserting the stopper partially into the vial, as is shownin FIG. 8. The cam is detachable, being held by a bolt 94. This permitssubstituting a dierent cam if the plunger is to be moved a greaterdistance, for example if the stoppering was with solid Stoppers insteadof slotted Stoppers, the former having to be pushed all the way in. Anexamination of FIG. 9 will show that when the plunger 82 is moved down,vacuum is cut off from the center of the plunger and therefore this willnot tend to pull the stopper back out from the vial as wheel 81 moveson.

The stoppering operation just described requires means for holding avial against tipping during the stoppering operation and keeping itproperly aligned with the wheel 81. This mechanism is shown in FIGS. 12and 13 and, in relation to the other elements of the stopperingmechanism, in FIG. 7. A wheel or plate 9S is located horizontally at thelevel of the vials as they move along. The wheel has a groove 96 whichcooperates with a narrow vial fence member 97. The lower plate of thewheel, which turns below the fence 97, is provided with contours havingbeveled sections 98 and notches 99, the latter adapted to receive thelower portion of a single vial. The upper plate has a similar contourbut the notched portions are in plungers 100 which are urged out bylsprings 101, (FIGS. 12 and 13).` The relative vertical position of theplates and the fence 97 is shown on FIG. 7 and is adjustable by thesupports 102 with slots 103 and bolts 104. This provides for fencepositioning, and an adjustable bracket 105 permits adjustment of theheight of the wheels 81 and 73.

Turning to FIG. 12, it will be seen that as the row of vials moves inthe direction of the arrow the track forces them to the right where theneck of each vial is engaged by the notch on one of the plungers 100.The cam shaped contours 98 space the vials apart so that different vialsare contacted by successive plungers. The spring pressure of the plungerin the positionshown on FIG. l2 at 106 holds the neck of the Vialtightly against one of the fences 97. It will be seen that in thisposition the fence has pushed the vial, and with it the plunger 100,somewhat in toward the center of the wheel, thus compressing thecorresponding spring 101. It is at this position that the Vwheel 81inserts the stopper into the vial. All of the wheels have to turn insynchronism and must be adjusted so that the wheel 81 and the wheel 95come to the same position at the same time. Precise adjustment is madepossible by slots 107 through which `bolts S clamp into the plate 109which drives the wheel. Very precise adjustment is made possible, whichis maintained for any particular size of vial.

After stoppering, as the wheel 95 continues to turn, the stoppered vial,which is shown at 110 on FIG. 12, is now free to move along the trackunder the urging of the conveyor belt. The vials are spaced as theyleave the stoppering station, which can 'be seen at the left in FIG. 1B,and the track now branches off, the vials being moved along the fence111. As their movement along this fence is slower than the forwardmotion of the conveyor belt 24, they move up together, as is also shownin FIG. 1B. Now they pass an electric eye 112 which counts the number ofvials until the number corresponding to the final packing tray 150 hasbeen lined up. In the drawings this is shown as twenty-one. A signal isthen given which initiates the transfer of .the row of twenty-one vialsto the iinal loading tray, which will now be described in conjunctionwith FIGS. 14 to 19. FIG. 16 shows the situation just after thetwenty-first vial has been counted. It will be seen that there is aframework 113 carrying a rake, which will be described more particularlyin conjunction with FIGS. 14 and 15. The framework slides on journals114 and 115 which can move along a rod 116.

The signal from 112 irst actuates a pneumatic cylinder 117, the plungerof which, 118, is shown in its retracted position in full lines in FIG.16 and in dashed lines in its extended position. As the plunger movesforward it strikes a hammer 119 which is pivoted on the framework 113.The hammer extends on underneath the top rail 120 of a pivotable rake.Turning to FIG. 14, which shows the plunger 118 in its extendedposition, an extension 121 of the hammer 119 strikes the lower rail 122of the rake which is pivoted in the framework 113 at 123. The two rails120 and 122 of the rake are connected together with posts 124 which canbe seen clearly in FIG. 16. The motion of the plunger 118 through thehammer 119 causes the lower rail 122 to pivot to a position from thatshown in FIG. 14. This position is shown in FIG. 15, which also showsthe plunger 118 which has now been withdrawn. It will be seen in FIG. 15that the upper rail 120 presses down on the tops of the Stoppers of therow of twenty-one vials.

The same signal from the electric eye 112 starts a reversible motor,(not shown) which moves the chain 125 in the direction of the arrowshown in FIG. 1B, a double arrow being shown in FIG. 16, to indicatethat the motor is reversible and at another point, which will bedescribed below, can turn the chain back to the position shown in FIGS.1B and 16. The chain is protected by Ia cover 126, which is shown partlybroken away in FIG. 1B and is omitted entirely from FIGS. 14 to 19. Thechain 125 moves on sprockets |127 turned by a shaft 128 which in turn isdriven by the reversible motor above referred to. As the chain 125 movesin the direction of the arrow in FIG. 1B, which is also to the right inFIG. 16, a pin 129 moves with it, and this pin extends through one ofthe links. The pin is rigidly attached to and forms part of the journal115 and therefore as the chain moves the framework 113 moves with it.This causes the rake to move the twenty-one bottles until the row isopposite the already loaded rows 130 of the nal unloading tray 150,which is shown in FIG. 1B. The ligure shows the rake and row of bottlesjust as it has started to move. FIG. 17 shows the rake and the row whenit has arrived in position opposite the tray 150. At this point the rowof vials is resting on a platen 131 and is separated from the loadedrows 130 by a movable fence 132.

In FIG. 17 it will be seen that the pin 129 has traveled almost to thesprocket 133 at the other end of the chain 125. At this point the travelof the framework 113 trips a microswitch, (not shown), the reversiblemotor stops, and a signal is given to two pneumatic cylinders 134 and135, which are most clearly shown together on FIG. 1B. The cylinder 134has a plunger 136 with a head having a triangular projection 137, (FIGS.17 and 18), fitting into a hole or notch 143 on the platen 131. Thewhole apparatus is strongly reminiscent of a stylized woodpecker withthe plunger 136 as his neck. As in the case of a real bird, the head canturn back from the platen 131, swiveling the cylinder 134 on a pivot139. At this point the platen is locked against movement by a projection140 on a cross shaft 141. The other end of the shaft is positioned on aplaten framework 142 so that a projection can be struck by the plunger138 of cylinder 135, (FIG. 1B). At the same instant the fence 132 israised by a pneumatic cylinder, (not shown), to the position shown inFIG. 18.

As both cylinders 134 and 135 have been energized, the woodpecker movesforward and the shaft 141 turns so that the platen 131 can move in thedirection shown in FIG. 18. This position corresponds to the maximummovement of the plunger 136, and it will be seen that the rotation ofthe shaft I141 has moved the projection 140 up so that the platen wasable to slide freely under it. Now the last bit of travel of thewoodpeckers head moves the platen to a point where the projection 1.40can fall into the next hole in the platen. These holes, shown at 143 onFIG. 1B and FIGS. 17 to 19, are spaced the width of a row of vials.

The raising of the fence 132 engages the upper rail 120 of the rake by aprojection, (not shown), flipping the rake back to its originalposition, which is shown in FIGS. 16 and 18. At the end of the platenmovement, just after the position shown in FIG. 18, a microswitch, (notshown), causes the fence 132 to drop to the position shown in FIG. 17,and the plunger 136 now moves back into its cylinder. This withdraws theplaten slightly until the sloping lower part of the woodpeckers beak hasraised the head sufiiciently so that it clears the hole 143 in theplaten. This is the position shown in FIG. 19 with the woodpeckers headslightly raised and ready to slide along the platen to finally drop intothe next hole 143, as shown in dotted lines in FIG. 19. The slightbackward movement of the platen 131 moves the loaded rows of vials 130against the last loaded row so that they fit snugly against the fence132. This is the position shown in FIG. 19. The same switch sends asignal to the reversible motor which turns the sprocket 127 and movesthe chain 125 in the reverse direction, bringing the rake back to itsoriginal position where it is shown in FIG. 1B and FIGS. 14 to 16. Therake is now ready to receive another row of twenty-one vials and torepeat the above described operation on the next signal from theelectric eye 112.

As row after row of vials is loaded onto the tray 150, the platen 131moves successive holes to the right, as shown in FIG. 1B, until finallya projection or dog 144 strikes a microswitch 145. This causes thecylinder 135 to unlock the platen by turning the shaft 141 clockwise andthe woodpecker head is slightly raised by pivoting the cylinder 134 bymeans which are not shown. The platen 131 is now free to slide and it ispulled back by the weight 146 which is connected to the platen by a cord147 running over a pulley [14S in the platen framework 142. The

platen is returned to its extreme position and is ready to receive thenext row of vials. However, the tray 150 is now full and so the signalfrom the microswitch 145 stops the whole operation of the line, thuspermitting the operator to remove the full tray 150, which is placed ina vacuum refrigerator if, as is the case with the slotted stoppers shownin the drawings, it is to be dried. Now the operator puts in an emptytray 150 and presses a start button, (not shown), which starts up theproduction line going through the sequence of operations which has beendescribed.

It will be noted that the holes 143 are spaced to permit the platen toslide on its guide rollers 149 one row of vials at a time. If vials ofdifferent diameters are to be run, another platen with suitably spacedholes is slid in and the operation proceeds as described above with thenew size of vials.

The above description is based on the use of presterilized vials. Ifunsterilized vials are used the conveyor 24 before reaching the fillingstation passes through a sterilizing tunnel and cooling tunnel such asare described in the patent to Taylor & Corley No. 3,058,177, dated Oct.16, 1962.

We claim:

1. An automatic, essentially continuous system for filling andstoppcring containers, comprising in combination:

(a) smooth surfaced conveying means for conveying containers through atleast filling and stoppering stations,

(b) means for automatically loading containers onto said conveying meansin at least one single file without empty spaces,

(c) means for maintaining each single file of containers on saidconveying means in a continuous line one container wide,

(d) filling means comprising filling nozzles for simultaneously fillinga predetermined number of containers in each line, said filling meansincluding a source of liquid to fill the containers and means forpumping a predetermined quantity of the liquid to each filling nozzle,said pumping means being comprised of means adjustable to pump apredetermined volume of liquid for each nozzle and means for isolatingsaid pumping means from the liquid to be filled into each container,said isolating means transferring to the liquid to be filled the samevolume as is pumped,

(e) means for adjusting the filling means so that the time for fillingsaid predetermined number of containers can be varied with respect tothe time for stopping the containers whereby the time required forfilling is slightly longer than the time required for stoppering,

(f) means for segregating in each line a predetermined number ofcontainers and means for moving said containers into position to receiveliquid from the filling means and to maintain them in position relativeto the nozzle during lling, said means operating in synchronism with thepumping means so that containers are moved into position during theportion of a pumping cycle in which liquid is not forced out andretaining them in position to receive liquid for a time at least as longas the liquid pumping time, and

(g) stopper inserting means vertically positioned over each line ofcontainers and means for loading said stopper inserting meansautomatically with Stoppers in proper orientation.

2. A system according to claim 1 comprising automatic means for removingfrom the line of containers any container which has fallen on its side,said means being positioned on at least one side of the filling meansand the stoppering means.

3. A production line system according to claim 1 comprising means forcounting stoppered containers, means for moving lines of containers fromthe stoppering station continuously past the counting means for eachfile, means actuated by the counting of a predetermined number ofcontainers to load the counted containers onto a receiving tray.

4. A system according to claim 1 comprising means for enclosingcontainer loading, filling, and stoppering stations, and means formaintaining within said enclosure a sterile environment.

5. A system according to claim 2 comprising means for enclosingcontainer loading, filling and stoppering stations, and means formaintaining within said enclosure a sterile environment.

6. A system according to claim 3 comprising means for enclosingcontainer loading, filling and stoppering stations, and means formaintaining within said enclosure a sterile environment.

7. A system according to claim 2 in which the means for maintainingcontainers in each line in single file comprises two tracks spaced byapproximately a container cross section and of height greater thancontainer cross section except at the point of ejection means forcontainers tipped on their side, at which point the lower portion of onetrack is cut outto a height slightly greater than a container crosssection for a distance at least equal to a container length and meansare provided for causing a container tipped on its side to move outsideways and be rejected through said cut-out portion.

8. A system according to claim 7 in which means are provided at aportion of the conveying means outside the area of filling means andtipped container rejecting means for cleaning off spilled liquid from atipped container.

References Cited UNITED STATES PATENTS 1,416,345 5/1922 Gosselin 53-28'2X 2,620,065 12/1952 Boyce 198-33 X 2,946,488 7/1960 Kraft 222-1342,952,955 9/1960 Leichenich et al. 53-61 3,369,642 2/1968 Hennig 198-333,431,702 3/1969 Spaulding 53-281 THERON E. CONDON, Primary Examiner R.L. SPRUILL, Assistant Examiner U.S. Cl. X.R. 53-l67, 282

